Insulating pad and the like and method of making same



Nov. 22, 1938.

Il@ z C. T. GOULD ET AL Filed March 17, 193'? Irwenor: Charles Z Gould, JerberZzMBonue- Patented Nov. '22, 1938 PATENT OFFICEy 1Ns` `TING PAD AND THE LIKE AND vrnon oF MAKING SAME charles T. dma and Herbert M. Bonney, Walpole, Mass.

Application March 17,

8v Claims.

This invention relates to cushioned padsl'which may be used for a variety of purposes, one of which is as an insulating pad forV use in the walls and roofs of buildings, and it'iurther relates to the method of making the same.

The main object of the invention is the pro` duction of a cushioned pad, the elements of which are united by a plurality of lock stitches so constructed that the said pad may be greatly inlo creased in thickness when thelling material expands while permitting the opposite facesJ of not limited to the precise arrangement and organization of these instrumentalities vas herein shown and described except as required by th scope of the appended claims.

Of the drawing- Y Figure 1 represents a plan of a pad embodying the' principles of the present invention, the stitches uniting the various elements thereof- 30 beingshown `drawn out and elongated.l p

Figure 2 represents a section of the same on line 2, 2 on Fig. 1, the elongated loops oi'vthe stitches being shown extending upwardly although in practice they never would assume this position but would lie at on vthe `upper side of the pad.

Figure 3 represents an inverted plan of the pad and showing the lock stitches.

Figure 4 represents a plan o-f the pad after the has expanded to its fullest extent.

Figure 5 represents an elevation of4 the same. Figure 6 represents an enlarged detail of one -of the-stitches uniting the various elements o'f the pad when `it has expanded to its fullest extent, and v v Figure 7 represents a detail showing the lock vstitch on the bottom of .the pad.

Similar characters indicate like parts throughout the several figures of the drawing'. In the drawing, III, II represent two sheets of iibrous covering material between which is inter.. posed a layer I2 of iluiy expansible illling material such as wool the sheets III, II being of such 55 a characterl as will prevent the tearing of the layer of wool between the upper and lower sheets ,1937, Serial No. 131,424

same during the construction of the pad or subsequently thereto.

The upper and lower sheets of material I0, II and the layer of filling material I2 interposed between them are united by a plurality of stitches I3, the locking portions of these stitches being beneath the lower sheet of material II.

When the elements of the pad are being stitched together thel pad is somewhat compressed, as shown in Fig. 2.

This pad in its vcompressed condition is fed intoa sewing machine by which the lock stitches I3 are formed by suitable stitching mechanism.

During this operation as each loop is formed by the stitching mechanism, it is seized and drawn out into elongated condition and extended above the upper sheet I as indicated at I4' in Figs. l and 2.

The elongated loop I4 of each stitch is retained inits extended position until the next stitch I3v is formed and then released.

By .this means each stitch I3 is very loosely formed making it possible for the upper and lower sheets Ill, II to further separate from each other when the pad is released from the sewing machine and the filling layer I2 begins to expand. Y

While the stitches I 3 are being formed the pad is about two inches in thickness as indicated in Fig. 2, but when the filling material expands the sheets I 0, II- may be separated to such an extent that the pad will be four or iive inches thick as shown in Fig. 5, thus making a very soft and compressible cushion which may be used for a variety of purposes, such as car seats and cushions for the backs of the seats.

Obviously, many kinds of lling material may be used in the layer I2 accordngto the purpose the pad is to be used.

One of the prime objects .of/the invention is to provide a pad in which the .layer I2 will be made of glass or mineral wool anda pad thus made 4is particularly desirable for insulating material in the walls and roofs of buildings.

By making the layer I2 of glass or mineral wool it will be reproof and also proof against vermin, which is of great advantage.

When the stitches I3 have been formed uniting the various elements Ill, II and I2 oi.' the pad;

the under side 4of the lower sheet- II has applied thereto an adhesive I extending over the lock stitches which holds the stitches in position rela.- tively to said sheet II, thus preventing any displacement of the thread forming the stitches vI3 while the pad is expanding to take up a part of the slack in the loops I 4 of the stitches.

In forming the pad the sheets of covering material III, II are flat and in parallelism, and when the pad expands from the condition shown in Fig. 2 to the condition shown in Fig. 5, showing the fullest expansion of the pad, these sheets I0, II remain in parallelism.

If a layer of lling material such as wool be tween two sheets was sewn together Vby tight stitches and then the `layer expanded, the sheets I0, II between the two rows of stitches would bulge out and the pad would have what is known asta biscuit eifect and obviously -this would be objectionable, particularly where the pad is Yto be used inthe walls or roofs of buildings as an insulating device.

In shipping the pads they may be compressed to a considerable extent with the surplus thread in loops Il laying flat on the upper surface of the pad and. when unpacked at their destination and placed in the cavities they are to flll the filling material will immediately begin to expand and greatly increase the thickness of the pad without permitting the opposite faces of the pad to get out of parallelism. The loops Il are of such a length as to permit the greatest expansion of the material between the two sheets without bending either sheet inwardly at any point.

The covering sheets III, II are preferably made of fibrous material having two sets of fibers crossing each other.

The covering sheets I0, II could be made either of' paper or-cloth and in some high temperature insulation work these sheets might be made of woven asbestos or cloth made of glasswool thread to resist extremely high steam temperatures up to a top limit of approximately 900.

Ordinarily the sheets are made of paper having I fibers embedded in asphalt between two sheets or paper and calendered into a single sheet. However, the formation of such sheets I0, I I forms no part of the present invention as the material used in these sheets is a patented product and purchased in the open market While throughout the specification the word "wool is referred to as the filling material, this wool may be of glass-wool, mineral wool, natural wool, or of any loose, soft fibrous material, or even formed of asbestos or kapok.

In Fig. 3 of the drawing is shown an adhesive I5 which extends over the lock stitches I3, this being a ready means of preventing the lock stitches from movement relatively to the under sheet II. A

It is obvious that other means might be employed to produce this same result. For instance, it is only necessary that the adhesive be put on to the thread so that when it hardens the thread is sized stillly and has the effect of a kinked wire preventing the loops from drawing through each other. It is also possible to do this with a thread that is sized before sewing and applying moisture to it after sewing, the moisture giving the thread a permanent set in the loop position. In constructing the pad it is intended that there shall always be some slackness in the loops I4, even when the pad has fully expanded.

It is believed that the operation and many advantages of the invention will be readily understood without further description.

Having thus described our invention, we claim:

l. The method of forming cushioned pads conslsting of feeding to a sewing machine two sheets of tough material between which is interposed a thick layer of compressed expansible wool, uniting said sheets and layer by a plurality of lock stitches, and drawing out the loop of each stitch above the upper sheet during the formation of the next stitch to a length sufficient to permit the extreme expansion of said wool.

2, The method of forming cushioned pads consisting of feeding to a sewing machine two sheets of tough material between which is interposed a thick layer of compressed expansible wool, uniting said sheets and layer by a plurality of lock stitches, drawing out the loop of each stitch above the upper sheet during the formation of the next stitch to a length suiicient to permit the extreme expansion of said wool, and subsequently releasing the drawn out loop after the fcrmation of the next stitch.

3. As a new article of manufacture, a cushioned pad consisting of two separated parallel sheets of covering material having between them a thick layer of compressed expansible material, said sheets being iiat and connected together by threads loosely stitched through said layer of material with elongated loops of surplus thread above the upper sheet thereby permitting further sepation of said sheets upon the expansion of said filling material, said sheets remaining flat and parallel during and after the expansion of said filling material. v

4. As a new article of manufacture, an insulating pad consisting of two separated parallel sheets of covering material having between them a thick layer of compressed expansible mineral wool, said sheets being fiat and connected together by threads loosely stitched through said layer of wool with elongated loops of surplus thread above the upper sheet thereby permitting further separation of said sheets upon the expension of said wool. said sheets remaining at and parallel during and after the expansion of said wool.

5. As a new article of manufacture, a cushioned pad consisting of two separated parallel sheets of covering material having between them a thick layer of compressed expansible filling material, said sheets being flat and connected together by threads loosely stitched through said layer of filling material with elongated loops of surplus thread above the upper sheet thereby permitting further separation of said sheets upon the expansion of said filling lmaterial, said stitches being locked together beneath the lower sheet and having above the upper sheet loops of suflicient length to permit the extreme expansion of said filling material without bending said sheets.

6. As a new article of manufacture, a cushioned pad consisting of two separated parallel sheets of covering material, a layer of compressed expansible filling material between said sheets, and a plurality of stitches extending through said filling material and sheets with loose elongated loops of surplus thread permitting a greatly increased separation of said sheets, the length of said loops being sufficient to permit said filling material to expand to a thickness over twice as great as its thickness when compressed Without bending either sheet from its normal flat plane.

7. As a new article of manufacture, a cushioned pad consistingof two flat sheets of brous cover` ing material in parallelism with a layer of compressed expansible filling material between them all connected togetherrby stitches, each stitch having an elongated loop of surplus thread extending above the upper sheet, said loops of surplus thread being adapted to permit a much greater separation of said sheets upon expansion of said lling material While permitting said sheets to remain in'parallelism during and after such expansion.

8. As a new article of manufacture, a cushioned pad consisting of two separated parallel sheets of covering material having between them a thick layer of compressed expansible filling material, said sheets being connected together by threads loosely stitched through said layer of filling materia! with loops of thread extending above the upper sheet thereby permitting a greatly increased separation of said sheets upon the expansion of said lling material without affecting the parallelism of said sheets, said stitches being locked together beneath the lower sheet and secured to said lower sheet by an adhesive substance.

CHARLEST. GOULD; HERBERT M. BONNEY. 

